Process of making embossed article and product thereof



Sept. 15, 1953 A, E, MURRAY 2,652,352

PRocEss o? MAKING EMBossED ARTICLE AND PRODUCT THEREOF Filed July 2s,194s 2 sneerssneet 1 INVENTOR `BaYn E. Mul-ra] AT'roRN A. E. MURRAY.l

Sept. 15,1953

PROCESS OF MAKING EMBOSSED ARTICLE AND PRODUCT THEREOF Fild .July 23,194s l 2 Sheets-Sheet 2 Patented Sept. 15, 1953 UNITED `STATES PATENTOFFICE PROCESSOF MAKING EMBOSSED ARTICLE AND PRODUCT THEREOF Alan E.Murray, New York, N. Y.

Application July 28, 1948, Serial N o. 41,058

14 Claims. 1

My invention relates particularly to a process and products thereofwhereby articles of sheet material of unusual properties may be producedand at a comparatively low cost with a minimum amount of labor, as forinstance blotters, book covers, writing table accessories, brief cases,belts, handbags, articles of clothing, leather jackets, gloves,gauntlets,` shoes, etc.

An object of my invention is to produce articles of this characterhaving a long life and which are not subject to the `usual amount ofwear by abrasion or otherwise. Another object is to provide embossingwhich has a high relief but which is, nevertheless, sustained andmaintained by materials which are oan elastic character, and which mayhave a backing on which the elastic embossing is supported. Furtherobjects of my invention will appear from the detailed description of thesame hereinafter, whereby accurate embossings can be obtained.

While my invention is capable of embodiment in many different forms andis capable of being carried out in many different ways, for the pur-`pose of illustration I have shown only certain forms of the products andapparatus for producing the same in accordance with my invention in theaccompanying drawings, in which- Fig. l shows a plan view of an embossedsheet material, such as leather, secured to a blotter, made inaccordance with my invention for making` group or mass-producedarticles;

Fig. 2 is a cross-section of the same, taken on line 2-2 of Fig. 1; l

Fig. 3 is a vertical section of an apparatus used in connection with ahydraulic or other press for producing` the same, taken on line 3-3 ofFig. 4; l

Fig. 4 is a plan view of the apparatus shown as removed from `thehydraulic press illustrated in Fig. 3;

Fig. 5 is a plan view of a sheet of paper having a design thereon`corresponding to the embossing shown in Fig. 1; and

Fig. 6 is a plan view of a blotter carrying an embossed leather thereonhaving an inscription made in accordance with a modification of myprocess for producing individualized articles, not necessarily to bemade by mass production.

In the drawings, for example referring first to Figs. 1 to 5, I haveshown a sheet of leather I, preferably such as soft kid or morocco orsoft calf skin, which has been treated and processed in accordance withmy invention, having an embossed margin 2 around the edge of the same asWell as an embossed inscription 3 thereon, the

margin 2 and inscription 3 being in high relief, and the `same beingsecured to one or more layers of blotting paper 4 as hereinafterdescribed.

In producing the embossed sheet leather I, I y

first make a design 4 for producing an accurate embossing, as forexample a signature or name in handwriting, with a pencil on a sheet ofpaper li. Thereupon, I trace the design 5 with carbon paper onto a rigidfiat plate of smooth, preferably absorbent, material such as wood, fibreboard, cardboard, etc., as for example a laminated ply-wood, l. With anarrow brush I then go over the design on thelaminated ply-Wood l so asto apply on the lines of said design a rubber cement of any desiredkind, as for instance made of rubber dissolved in a volatile solvent,such as a hydrocarbon, and allow the cement to dry until it becomestacky. Then I prepare a readily bendable cord of any desired kind, butpreferably a hard twisted or woven fish line or chalk line B made oftextile fibres, by brushing the said line or cord with more of the saidrubber cement and allowing the same to dry until tacky, thus producing atacky, readily adherent, rubber coated cord. This rubber coated cord isthen cut into small pieces of any convenient length, but preferably suchas to require two or more pieces thereof for each letter of thesignature or name, or of such size that each piece may readily form eachof the loops or straight lines of the signature made in a fiat plane, asdesired. These pieces of the rubber coated cord 8, while still tacky,are made to adhere end to end, to produce the lines, over lthe tackyoutline which has been made on the ply-wood l. The said pieces 8 firmlyadhere thereto and the pieces are then pushed around with a blunt stylusuntil they accurately occupy the exact outlines, as desired, of theinscription, as well as the marginal lines, preparatory to producing thedesired lines of the embossing. The tackiness of the cord and the lineson the ply-wood l enable a great deal of accuracy to be attained inconforming the pieces of cord to the desired out-lines, and such as toproduce the high relief of the embossing. Then I apply to the surface ofthe ply-wood 'l carrying the pieces of cord B fixed in place thereon,one or more layers of a hard coating, but preferably about two layers,of a cellulose ester solution comprising cellulose acetate, for example,carried in any desired volatile solvent or solvents, When the solventshave evaporated there remains a hard coating which is not soluble inrubber cement or rubber compositions, and an effective positive die isthus obtainedcomprised of the laminated ply-wood l having thereon therubber encased cords 8. A negative die il is then formed of a body ofcompressible elastic vulcanized rubber or articial rubber, preferablyneoprene, which may be of any desired thickness but which, for instance,is 1/4 in thickness, or, as for instance, about double the thickness ofthe laminated ply-wood l. The surface of the rubber plate 9 can be roughor smooth, but preferably in using the die I rst use one face vhich issmooth and then the opposite face which has a pebblelike surface forcausing the rubber plate to conform itself completely to the cords 2iand the surface I supporting the cords. Furthermore, the rubber plate 9may be supported upon a wooden block it, to the upper face of whichthere are attached, by screws Il, lateral guides it and I3 andlongitudinal smaller guides I4 and i5, the said guides being made ofwood or of any other desired material, so as to be held in place by thescrews I I and the negative die wooden block it. The positive die l andthe negative die 9 with its supporting plate I0, can then be placedbetween upper and lower jaws it and il oi a hand screw press so that anydesired amount pressure may be exerted thereon by power or otherwise.

Thereupon, I prepare two solutions of any adhesives desired, butpreferably of neoprene latex. In this connection, I use latex, which isa long established well known liquid comprising a pre-vulcanized latexor a self-vulcanizing latex or a pre-vulcanized or self-vulcanizedsynthetic rubber substitute, as for instance neoprene, in

the form of a liquid, that is to say a water susi pension of the rubberor rubber substitute prepared so as to be selfnvulcanizing when allowedto set. Also, I p refer to use two diiferent strengths or consistenciesof the said liquid latex, which may denominate for the purposes hereinas #1l-thin neoprene latex having the consistency of thick milk#t2-thiol: or thickened neoprene latex having the consistency of a Veryheavy cream.

These are both well known commercially available liquids known asneoprene latex, and which will, for convenience, be referred tohereinafter merely as latex The thin latex #l can, if desired,be'prepared by adding two parts of water by volume to one part by Volumeof the thickened latex #2, Thereupon 1 take a sheet of fiat soft kidleather of any desired color, or any soft grained leather I, generallycalled morocco or kangaroo, or a very soft calf skin, but which may beany soft grained leather. This sheet of flat leather I is then saturatedby applying with a brush, on the esh side of the leather, the thin latex#1, after which the excess of the latex is brushed off. Then Iimmediately brush onto the leather,` on the flesh side, some of thethick #2 latex so as to make a surface covering over the entire surfaceof the impregnated leather.

The negative rubber die pad 9 is now immersed in soapy water at atemperature of about 150 F., or any other desired temperature, whichrequires generally from five to ten minutes. This makes the pad 9 softand wet, and the soapiness thereof prevents it from sticking to theleather containing the latex. From time to time, during the time whenthe negative die pad 9 is being used the pad can be again immersed inthis way to maintain the properties thereof just referred to. Thereupon,1 apply an emollient miscible with the water of the latex, such as asoap and preferably saddle soap, on a cloth moistened with water to thehair side of the leather I and rub it in with the cloth in order tosoften the hair side of the leather and to effectively remove allunabsorbed latex that might be on this side of the leather. The fleshside of the leather i, while wet with the latex, is now placed againstthe hard cords 8 Which are encased in the hard cellulose ester, next tothe positive die 'i substantially immediately, before Vthe latex hasgelled and before it has set. The jaws it and il of the hand screw pressare now brought together so as to thereby apply power pressure theretoand to produce any desired pressure greater than mere hand pressure, asfor example 1000 to 4000 lbs., so as to produce the impression of theembossing in theleather i before the latex which is absorbed in theleather has gelled and to fill the cavities of the embossing with thelatex. The pressure of the hand press causes the thick latex topenetrate thoroughly every part of the leather I and into theconcavities of the embossing over the cords 8, and this makes the latexgel quickly because of the interaction ci the thick latex and theconstituents of the leather, as for instance the chromium compound orcompounds which are normally present in chrome tanned leather when theleather has been produced by chrome tannage, although, as a matter offact, theconstituents which have been added to or formed insubstantially any leather which has been tanned by the Various tanningprocesses will cause the latex to gel almost immediately under thepressure applied. The treated leather i is allowed to stay in the pressfor any desired time, but usually three minutes is sufficient to causethe latex to gel. The jaws of the press I6 and il are then separated andthe leather I can be lifted off readily with the positive die l as itwill not stick to the soapy rubber surface oi the negative die pad t.The hair side of the treated leather i such as saddle soap and a clothwet with water to remove the unabsorbed latex from the surface of thehair side of the leather, after which the leather is stripped olf fromthe positive die 'I. The flesh side of the leather thus freed from thepositive die 'l is then brushed with some of the thick latex #2, so asto fill the concavities of the embossing with the said latex and then,while this latex is still wet, I apply a backing of an absorbentmaterial, such as the blctter il, to the treated leather I, to which thesaid biotter l becomes firmly adherent. When the latex has entirelygelled, which generally takes place in a few minutes, the latex ofrubber or rubber substitute will be found to have lled the intersticesof the leather and the concavities of the embossing entirely, and afterstanding for a longer period, as for instance about ten days, the rubberwill be found to have completely set into a 'tough resistant and elasticsolid. This preserves the detail of the embossing in the impregnatedleather, which is set into the embossed form with a high relief andwhich is maintained elastically in this form due to the latex fillingall the interstices of the relief portions of the embossed leather. Theembossing thus obtained, accordand Iis not subject to any Iappreciablematerial deformation or damage due to use. This is particularlyimportant in articles which are subjected to continued use, as forinstance in the articles named above.. Accordingly, the articles is thenagain rubbed with the emollient,`

ingly, remains permanent as Well as waterproof,A

on the sheet of leather I.

thus produced are notable for freedom from wear.

` The modification of my invention as set forth in Fig. 6, isparticularly suitable in connection with the making of `individualizedembossed articles and `which do not require mass production. This isparticularly suitable for individualized articles having thereon. forinstance, the individual signatures of their respective owners. Forexample, in making a desk blotter I make a design on paper, of theembossing desired, similar to that on the sheet of paper E abovereferred to, and then I trace over this onto a hat smooth, preferablyabsorbent, sheet of material, such as a blotter I8, with the aid ofcarbon paper, the design which is to be embossed thereon. The design ofthe embossing thus produced on the blotter I8 is then painted over withthe rubber cement, as described previously. Also, one or morecords I9are coated with rubber cement, as in the case of the cords 8 previouslydescribed, and while the design and the cords I9 are still tacky thecords, cut into small pieces, are applied to the design and made toadhere to one another their longevity and "thereon end to end. With astylus, as above described, the cords are shoved into place or bentaround to form the accurate design of the embossing. The cords I9 andthe adjacent face of the blotter are thereupon given one or morecoatings of a hard coating, such as the cellulose ester, for instancethe cellulose acetate solution above referred to, to completely coverthe cord and to form a stiff or hard coated backing. A sheet of leather20 of the character above described is then impregnated and coatedthroughout the body thereof, as described above in connection with thesheet of leather I. The leather 20, while wet, is nowplaced, flesh sidedown before the latex is dry, on top of the blotter IB carrying therubber coated cords I9. A rubber plate, such as Lthe rubber plate 9, isthen pressed down on the ltop of the leather by the screw hand press toprovide power pressure, by which I mean greater `than mere handpressure, first with the smooth side of the plate 9 and then with therough side of the plate 9 against the leather, which fills theconcavities of the embossing with thelatex. A blunt stylus can then bemoved over the top or hair side of the leather 20 around both sides ofeach of the cords I9 in the design to be embossed and the emollient,such as saddle soap, with the aid of a wet cloth, is rubbed over theouter or hair surface of the leather 20. This procedure, alternatelywith the stylus and the saddle soap, is repeated several times until theembossed de- .s sign shows in very high relief, and which is even higherthan the relief of the embossing shown In this way, and due 'to thepressure of the rubbing and with the stylus, the latex thoroughlyimpregnates the leather 20 and quickly gels due to the pressure appliedand leather.

to the effect ofthe constituents of the tanned Some of the latex evencomes through to the outer surface of the leather 20 in the l course ofthe pressure thus applied, which is removed by the said rubbing.Accordingly, the L latex completely fills the interstices of the leatherf as well as the concavities on the under surface of the embossed orraised portions of the design.

The underneath side of the coated blotter I8 can then have fastenedthereto, with an adhesive or f otherwise, one or more additionalblotters 2l 1 and 22, to form a backing.

Accordingly, the finished product, especially after the latex has becomecompletely set, in the `form of my invention in Fig. 1 as well as in thetegral whole. An elastic, waterproof, permanent embossing is thusobtained which, because of its great elasticity, is notsubject to theusual wear and damage by abrasion, of embossed materials as previouslymade; These advantageous characteristics are particularly valuable inthe articles of this character owing to the continual rubbing anduse towhich articles of this kind are normally subjected. Also, the embossedleather, notwithstanding its completely natural appearance, hasnevertheless coalesced throughout with the impregnating rubber so thatthe resulting article, while `having the appearance of natural leather,has the advantageous properties and characteristics of the rubber whichis present throughout the body of the same. i

While I have described my invention above in detail I `wish it to beunderstood that many changes may be made therein without departing fromthe spirit of the same."` l

I claim:

1. A process which comprises producing an embossed leather containing inthe leather and in the concavities of the embossing a unitary continuousbody of latex by embossing leather out the body thereof with latex,embossing the leather while wet by' applying power pressure to fill theconcavities of the `embossing with the latex while wet, pressed fromwithin the body of the leather, and allowing the latex to gel whilemaintaining the leather in the embossed shape.

2. A process which comprises producing an embossed leather containing inthe leather and in the concavities of the embossing a unitary continuousbody of latex by embossing leather wet to a point approximatingsaturation throughoutthe body thereof with latex, embossing the leatherwhile wet by applying power pressure to illl` the concavities of theembossing with the latex while wet, pressedfrom within the body of theleather, and allowing the latex to gel while maintaining the leather inthe embossed shape,

.the leather also having had latex introduced into the concavities ofthe embossing before the rst mentioned latex has completely set afterremoving the pressure. i

3. A` process which `comprises producing an embossed leather containingin the leather and in the concavities of the embossing a `unitarycontinuous body oflatex by embossing leather wet to a pointapproximatingsaturation throughout the body thereof with latex, embossing the4leather while wet byA applying power pressure to `iillgthe concavities1ofthe embossing with the tinuous body of latex by embossing leather wetthroughout the body thereof with latex, then applying an amount of athicker latex, embossing the leather by pressing the leather in a planeon one side bodily against a linear opposing force on the other sidewhile wet and allowing the latex to gel While maintaining the leather inthe embossed shape.

5. A process which comprises producing an embossed leather containing inthe leather and in the concavities of the embossing a unitary continuousbody of latex by embossing leather wet to a point approximatingsaturation throughout the body thereof with latex, then applying anamount of a thicker latex, embossing the leather by pressing the leatherin a plane on one side bodily against a linear opposing force on theother side while wet and allowing the latex to gel while maintaining theleather in the embossed shape, the leather also having had latexintroduced into the concavities of the embossing before the iirstmentioned latex has completely set after removing the pressure.

6. A process which comprises producing an embossed leather containing inthe leather and in the concavities of the embossing a unitary continuousbody of latex by embossing leather wet to a point approximatingsaturation .throughout the body thereof with latex, then applying anamount of a thicker latex, embossing the leather by .pressing theleather in a plane on one side bodily against a linear opposing force onthe other side while wet by applying power pressure to llstheconcavities of the embossing with the latex pressed from within the bodyof the leather and allowing the latex togel while maintaining theleather in the .embossed shape, the leather also having hadrlatexintroducedinto the concavities of the embossing before the iirst mentioned latex has completely set after removing the pressure, theembossed leather having a stiff` coated atbacking adherent to theleather below the embossing.

7. An embossed leather comprising ka plane leather surface withconcavities carrying therein a continuous `body of gelled latexiillingthe concavities of the embossing therein and extending throughout theformed body of the leather.

8. An embossed leather comprising a plane leather surface withconcavities carrying therein a continuous body of gelled latex fillingthe ernbossing therein and extending throughout the formed body of theleather, the embossing having the form of cords pieced-end to end.

9. An embossed leather comprising a plane leather surface withconcavities carrying therein a continuous body of gelled latex `illingthe embossing therein and extending throughout the formed body of theleather, the embossing having the form of cords pieced end to end, saidembossed leather having a stilf coated backing adherent thereto belowthe embossing.

l0. An embossed leather comprising a plane leather surface withconcavities carrying therein a continuous body of gelled latex fillingthe embossing therein and extending throughout the formed body of theleather, the embossing having the form of cords pieced end to end, saidcord also having a hard coating thereon.

1l. An embossed leather comprising a plane leather surface withconcavities carrying therein a continuous body of gelled latex llingtheV embossing therein and extending throughout the formed body of theleather, the embossing having the form of cords 4pieced end` to end,said embossed leather having a stiff coated backing adherent theretovbelow the embossing, said vcord also having a hard coating thereon.

l2. An embossed `leather comprising a plane .leather surface withconcavities carrying therein a continuous ,body of gelled latex'llingthe concavities of the embossing therein and extending Ithroughout theformed body of .the leather, the

embossing having therein also a cord.

13. The process which comprises producing an embossed leather containingin the leather and in the ,concavities of the embossing a unitarycontinuous body of .latex by embossing leather wetthroughout the bodythereof with latex,em

ebossing the leather while wet by applying pressure to lill theconcavities of the embossing with thelatex while wet, pressed fromwithin the body .of the leather, and allowing the latex to gel byaccelerating the setting thereof due to a constituent present in theleather, while maintaining the leather in the embossed shape.

le. A process which comprises producing an embossed leather containingin the leather and vin the concavities of the embossing a unitary,continuous ,body of latex by embossing leather `wet throughout the bodythereof with latex, embossingthe leather while Wet by applying pres-`also having vhad Alatex introduced into the con- `cavities oi theembossing before the rst mentionedvlatex has l'completely set afterremoving the pressure.

ALAN E. MURRAY.

Y,Referc-:nces Cited in the file of this patent UNITED STATES PATENTSNumber Name Date r Re. 19,847 Springer Feb. 4, 1936 v182,363 Kent Sept.19, 1876 589,260 Hulbert Aug. 31, 1897 1,758,186' Bendelari May 13, 19301,995,828 Troy Mar. 26, 1935 2,046,000 Sart June 30, 1936 2,061,922 RossNov. 24, 1936 2,130,222 Barrett Sept. 13, 1938 2,284,727 Cunnington June2, 1942

3. A PROCESS WHICH COMPRISES PRODUCING AN EMBOSSED LEATHER CONTAINING INTHE LEATHER AND IN THE CONCAVITIES OF THE EMBOSSING A UNITARY CONTINUOUSBODY OF LATEX BY EMBOSSING LEATHER WET TO A POINT APPROXIMATINGSATURATION THROUGHOUT THE BODY THEREOF WITH LATEX,EMBOSSING THE LEATHERWHILE WET BY APPLYING POWER PRESSURE TO FILL THE CONCAVITIES OF THEEMBOSSING WITH THE LATEX WHILE WET, PRESSED FROM WITHIN THE BODY OF THELEATHER, AND ALLOWING THE LATEX TO GEL WHILE MAINTAINING THE LEATHER INTHE EMBOSSED SHAPE, THE LEATHER ALSO HAVING HAD LATEX INTRODUCED INTOTHE CONCAVITIES OF THE EMBOSSING BEFORE THE FIRST MENTIONED LATEX HASCOMPLETELY SET AFTER REMOVING THE PRESSURE, THE EMBOSSED LEATHER HAVINGA STIFF COATED FLAT BACKING ADHERENT TO THE LEATHER BELOW THE EMBOSSING.